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Process Equipment Division GEA PHE Systems
Plate Heat Exchangers
Sugar IndustryA refined campaign to save energy
Refinement of energy savingThroughout the world the demand for sugar is increasing, allied to this, production costs are also escala-ting. This is the reason innovative engineering solutions are required in this market. Increasing thecapacity in sugar production does not only radically change the energy balance of a factory, but also in-fluences the quality of the product. GEA PHE Systems therefore offers you a state-of-the-art and carefully matched range of equipment for evaporation, condensation and general heating/cooling. Thus inputted energy can be fully exploited by using modern and powerful engineering!
The energy requirements of sugar production are particularly high, waste exhaust vapours and conden-sates, for example, must be recycled several times. At the same time the sugar solution must be handled in all process stages with as much care as possible. This is why especially short residence times, high heat transfer rates and small temperature differences are called for in the manufacturing process. Using the latest plate technology from GEA PHE Systems you can easily achieve these goals. Because our plates en-sure that multiple use of the energy guarantees low temperature differences and a reduction of the evapo-ration pressure without any problems, making the complete sugar manufacturing process more profitable from both energy and business management aspects.
More efficiency for your energy balance
5000
4000
3000
2000
1000
0
0 20 40 60 80
OH
TC (
k-va
lue)
W/m
2K
Brix
GEA PHE Systems EVAPplus evaporator in the sugar industry
GEA PHE Systems Concitherm 193
Robert evaporator
OHTC over dry substance
Within the GEA Process Equipment Division of the international GEA Group, GEA PHE Systems is responsible for plate heat exchanger technology. Strong individual companies: GEA Ecoflex, GEA ViEX, GEA WTT, GEA Ecobraze and GEA PHE Systems NA with production locations in Germany, Sweden, the USA, Canada and India produce gasketed, fully welded and brazed plate heat exchangers for worldwide distribution for use in almost all industrial applications. GEA EcoServe – the GEA PHE Systems service organisation – operates customer service centres in many countries to provide a rapid and competent maintenance and spare parts service, all around the world.
Concentrating on competence – for your benefit
Tailor-made solutionsThe range of GEA PHE Systems products for the sugar industry includes:
Plate heat exchangers:
Varitherm and NT Series for syrup, molasses, concentrated juice, filtered thin juice, extraction water
Free Flow for raw juice and limed juice as well as for unfiltered juices
Plate evaporators:
Concitherm as booster for Robert evaporator or complete stage EVAPplus as retrofit solution or complete stage
Direct contact condensers:
VAPORplus as retrofit solution or complete unit
Engineering – consulting:
Heat balance of evaporation stations Consulting for all evaporator types Design of condensers Design of condensate cigars
GEA EcoServe:
GEA EcoServe – the service organisation of GEA PHE Systems – offers you an extensive international service network. Whether you use products by GEA PHE Systems or by another manufacturer – at GEA EcoServe you receive complete service from a single source, whenever and wherever you need us. For maintenance and repair we use high-quality spare parts exclusively for all makes. This guarantees reliable seating, optimum function and a long service life.
Sugar Factory in Belgium Evaporation station with 8 effects
Proven in sugar beet campaigns GEA PHE Systems is able to cater for the complete range of thermal processes
arising in the sugar beet campaign – with EVAPplus falling film evaporators and Varitherm, NT Series, Free Flow and Concitherm plate heat exchangers. These special system components are integrated into the individual process stages.
Washing
Slicer
to the pulp dryerPress water
Extraction water
Pulp press
Liming
Milk of lime
1. Carbonation 2. Carbonation
Clarifier or Filter
Beet unloading and storage Extraction Juice clarification
Filter
CO2 CO2
Lime-Kiln
Limestone,Coke
Raw juice
Concentratedjuice
Sugar dryer
White sugar II White sugar I
Filter
Filter
Tanks
Crystallisation
Steam Steam
Mashes
Centrifuges
Syrup
Syrup
Mingler
Whitesugar I
Rawsugar II
11
10
12 13
14Syrup
Magma for seed
Final molasses
Seal water
Injectionwater
Thin juice
Finalproduct
Whitesugar II
Panvapour
Turbine exhaust steam
16
Concitherm
Multi-effect evaporation
edcba
Evaporation
Condensate cigar
15
Condensation
17
12
2
3
4
5
1
8
9
6 7
For all these applications:
1. Heating extraction water, Varitherm/NT Series 2. Heating press water, Free Flow (with solids) 3. Heating circulation juice, Free Flow 4. Heating raw juice, Free Flow 5. Heating limed juice, Free Flow 6. Heating carbonatation juice, Free Flow 7. Heating clarified juice, Varitherm/NT Series or Free Flow 8. Heating thin juice, Varitherm/NT Series 9. Multi-effect evaporation, EVAPplus 10. Heating concentrated juice, Varitherm/NT Series 11. Heating syrup, Varitherm/NT Series 12. Heating syrup, Varitherm/NT Series 13. Heating syrup, Varitherm/NT Series 14. Heating clearing liquor or remelt, Varitherm/ NT Series (without solids), Free Flow (with solids) 15. Heating magma for seed, Free Flow (with crystals) 16. Cooling of molasses with Varitherm/NT Series or Free Flow 17. Booster with Plate Evaporator Concitherm 193
Washing
Slicer
to the pulp dryerPress water
Extraction water
Pulp press
Liming
Milk of lime
1. Carbonation 2. Carbonation
Clarifier or Filter
Beet unloading and storage Extraction Juice clarification
Filter
CO2 CO2
Lime-Kiln
Limestone,Coke
Raw juice
Concentratedjuice
Sugar dryer
White sugar II White sugar I
Filter
Filter
Tanks
Crystallisation
Steam Steam
Mashes
Centrifuges
Syrup
Syrup
Mingler
Whitesugar I
Rawsugar II
11
10
12 13
14Syrup
Magma for seed
Final molasses
Seal water
Injectionwater
Thin juice
Finalproduct
Whitesugar II
Panvapour
Turbine exhaust steam
16
Concitherm
Multi-effect evaporation
edcba
Evaporation
Condensate cigar
15
Condensation
17
12
2
3
4
5
1
8
9
6 7
Magma for seed
Cane feed
Knives
A B C
Extraction Juice clarification
Multi-effect evaporation
Turbine exhaust steam
Concentrated juice
Filter
Tanks
Steam Steam Steam
Crystallisers
Syrup Syrup
Commercial sugar / Raw sugar
Centrifuges
Mixer
Molasses
Mingler
Injectionwater
Seal water
Lime-Cake
Press filter
FilterClarifier
CO2 or SO2
Milk of lime
Screen
Thin juice
Mixed raw juice
Milling plant
Bagasse
Liming
Extraction water
Syrup
13
Panvapour
b ca
Crystallisation
Evaporation
Condensate cigar12
Condensation
11
7
6
2
3
4
5
1
8
9 10
Reliable in sugar cane processingGEA PHE Systems plate heat exchangers have proven to be highly flexible across the full range of applications in the sugar industry. Whether beet, cane or other starchy products, the components work reliably and offer complete operational safety – even under extreme conditions.
Advantages
Compact, lightweight apparatus Large selection of materials Proven plate design
Reliable functioning Easy to clean and maintain Low space requirements
Magma for seed
Cane feed
Knives
A B C
Extraction Juice clarification
Multi-effect evaporation
Turbine exhaust steam
Concentrated juice
Filter
Tanks
Steam Steam Steam
Crystallisers
Syrup Syrup
Commercial sugar / Raw sugar
Centrifuges
Mixer
Molasses
Mingler
Injectionwater
Seal water
Lime-Cake
Press filter
FilterClarifier
CO2 or SO2
Milk of lime
Screen
Thin juice
Mixed raw juice
Milling plant
Bagasse
Liming
Extraction water
Syrup
13
Panvapour
b ca
Crystallisation
Evaporation
Condensate cigar12
Condensation
11
7
6
2
3
4
5
1
8
9 10
For all these applications:
1. Heating extraction water, Varitherm/NT Series 2. Heating raw juice, Free Flow 3. Heating limed juice, Free Flow 4. Heating carbonatation juice, Free Flow 5. Heating clarified juice, Free Flow 6. Heating thin juice, Varitherm/NT Series 7. Multi-effect evaporation, EVAPplus 8. Heating concentrated juice, Varitherm/NT Series 9. Heating syrup, Varitherm/NT Series10. Heating syrup, Varitherm/NT Series11. Heating magma for seed, Free Flow 12. Cooling of molasses with Varitherm/NT Series or Free Flow 13. Booster with Plate Evaporator Concitherm 193
EVAPplus for your economic success State-of-the-art technology, functionality and operational safety,
these are qualities typified by the EVAPplus falling film evaporators from GEA PHE Systems. This powerful plate evaporator is fully welded and therefore offers total product integrity. These plate evaporators have been increasingly and successfully used in the beet and cane sugar processing industry for more than 10 years.
With its special plate structure, high heat transfer values (calo- rific value) can be achieved at low temperature differences (∆t).
Due to the short residence time, the evaporation is kind to the product and thus reduces colour formation.
The peripheral costs, e.g. of circulation pumps, and the electrical energy requirements are lower because of the reduced coverage (wetting of heating surface).
The EVAPplus juice distribution is patented. Space requirements and weight are lower as compared to tube
evaporators. With the modular design of the plates, erection and installation
can be done quickly. Retrofitting is an easy process to increase the surface area
and performance of existing Robert evaporators. Additional plate packs can significantly increase the heating
surface and therefore the capacity even at a later date.
Unit with internal lamellar separators and internal
vapour channels
Unit with internal cyclone separators and external
vapour channels
approx. 1,000 – 10,000 m2
approx. 1,000 – 10,000 m2
8,6 min 122 min
2000
0
0
10000
8000
6000
4000
40 60 80
Co
lou
r (I
E 42
0)
Juice residence time (min)
100 120 14020
Juice-residence time
GEA PHE Systems plate falling film evaporator Colour formation
Robert Colour formation
Full programme throughout the process
The range of GEA PHE Systems plate heat exchangers is as diverse as the production stages in the sugar industry. Our range includes a wide selection of both models and materials, i.e. the suitable component for every single stage of the process. Tailor-made for your specific needs and your specific plant.
NT Series – the new plate generation
Optimum design due to variable lengths and profiles Low investment due to maximum heat transfer Self-positioning plate package (anti-waving)
Varitherm – for variable applications of any size
variable in performance, design and material selection heat exchanger surfaces from 0.1 to 2,000 m2 per unit throughput volumes up to 3,600 m3/h per unit nominal connection diameters up to DN 500
Free Flow – easy treatment of difficult media
designed for viscous, fibrous and solid-loaded media flow channels up to 12 mm plate spacing
Concitherm – getting really steamed up
concentrates liquids by evaporation 3 m2 heating surface per laser-welded cassette nominal connection diameters up to DN 600 free flow channels up to 7.5 mm plate spacing
Concitherm CT 193
Retrofit for low investmentEven existing plants can be optimised in their essential functions at favourable cost. Installation is carried out in 4 steps by converting existing Robert evaporators to EVAPplus falling film evaporators. This retrofitting process continues to use the existing vessels, resulting in high benefits at low investment.
Doubling or tripling the heating surface in existing Robert evaporators
Capacity increase of up to 300% with unchanged space requirements
No reconstruction works necessary to foundations or buildings
Existing pipework used to the greatest possible extent
Higher quality thanks to the improved thermal properties
Up to 40% savings in investment costs in comparison with installing a new evaporator
5% Pipework & valves0% Building & foundations3% Structural Steelwork
5% Structural Steelwork6% Building & foundations
20% Pipework & valves
4% Engineering6% I & C
5% Lagging
20% Vessel34% Heating surface
Save 43% ofyour total costs!
Four steps to new performance
Old Robertevaporator
Removing the baseplate
Removing the tube bundle
Installation of distribu-tion and plate packs
Installation of the base plate & start-up
~ 1,000 m2 ~ 2,000 m2 – 3,000 m2
Step 1 Step 2 Step 3 Step 4
VAPORplus – The difference is in the detail
Optimum energy exploitation also means making use of the vacuum exhaust vapours to heat up falling water for raw juice preheating. GEA PHE Systems offers either new supply or conversion of complete plants. VAPORplus-mixed condensers have been developed with specially designed distribution nozzles to achieve particularly thin water films. The large surface area guarantees intensive intermixing of waste vapours and cooling water, thus ensuring an extremely efficient con-densation effect. VAPORplus offers more:
Increased capacity Reduction of pressure drop Increase of falling water temperature Conversion of existing condensers is possible Optimum heat recovery
Leading sugar factories rely on GEA PHE Systems
GEA PHE Systems combines modern evaporation engineering with advanced plate technology. What counts is our know-how: Over 70 EVAPplus units have been commissioned world-wide to date – equivalent to around 200,000 operating hours of experience with su-gar. Exploit these assets for your campaign. A selection of current references:
Tirlemont Refinery, Wanze, Belgium Südzucker, Ochsenfurt, Germany Pfeifer & Langen, Könnern, Germany Amalgamated Sugar, USA Zillo Lorenzetti, Barra Grande, Brazil Jatitujuh, Indonesia Tableland, Australia Khanh Hoa, Vietnam Beghin Say, France Eridania Russi, Italy HSI Larissa, Greece Nordzucker, Klein Wanzleben, Germany
Südzucker, Ochsenfurt, Germany
European Sugar Factory
• HVAC
• refrigeration
• sugar
• chemical
• paper
• food
• life science
• marine
• power
• renewable energy
GEA PHE SystemsCompetence in Heat Transfer
With emphasis on the highest quality standards and constant innovations, GEA PHE Systems continues to expand its market position: Within the GEA Process Equipment Division, GEA Ecoflex together with GEA ViEX, GEA WTT, GEA Ecobraze, GEA PHE Systems NA and GEA EcoServe forms GEA PHE Systems, the Center of Competence and Service Center for gasketed, fully welded and brazed plate heat exchangers of GEA Group:
Contact details at:
www.gea-phe.com
Tech
nica
l mod
ifica
tion
rese
rved
· Su
gar
· E ·
05/0
8 fr
eita
g va
n ge
igk
The specifications contained in this printing unit are intended only to serve the non-binding de-scription of our products and services and are not subject to guarantee. Binding specifications, especially pertaining to performance data and suitability for specific operating purposes, are de-pendent upon the individual circumstances at the operation location and can, therefore, only be made in terms of precise requests.
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Process Equipment Division
GEA Ecoflex GmbHKarl-Schiller-Straße 1-3, 31157 Sarstedt · Germany Phone.: +49 5066 601-0, Fax: +49 5066 [email protected] · www.gea-ecoflex.com
GEA Ecoflex GmbHSchifferstraße 20 – 22, 47059 Duisburg · Germany Phone: +49 203 984 20-0 · Fax: +49 203 984 [email protected] · www.gea-ecoflex.com